Kickstart teeth fouling endplate - Cyclone

[john.t5]

This is the endplate from my mates TS1 after having the cyclone in it, it's a SIL endplate with an innocenti layshaft, now the endplate seems to have been machined down around the bearing 'holder' where the shim sits.

I started with a 1.8mm shim and the gears wouldn't turn so went down to 1.6mm and it was free so went with that, however if I set 1st gear and shim on to the endplate while out of the engine it is clear that the kickstart teeth are rubbing the endplate - can't quite get my head around it!!

Anyone make any sense or am I just rambling, I was going to just try another endplate but I would like to get my head around the cause anyway!

[wurzel]

The endplate hasn't been fitted without the layshaft shim has it?

[wack 63]

I've just measured a few Innocenti layshafts with the cyclone gears fitted and found between 0.7mm to 1.8 mm difference in the step between 1st gear and the lay shaft end which puts the 1st nearer to the endplate with the bigger step . The kickstart teeth are 3.16 mm deep on the cyclone compared to 3mm on a Jet200 one which when laying an endplate on with a 1.8 shim gives minimal clearance. Also noted that the layshaft end sits 3.85mm lower in the endplate bush so the bearing isn't fully supported, maybe it can be tapped down a small amount or a shim fitted under its collar? Bear in mind that these measurements are measured with the layshaft in a vice and the gears slipped on rather than in a casing but they will be the same anyway. The only way I can see getting some clearance on the endplate would be to have a groove machined for the kickstart teeth?

[Adam_Winstone]

As well as variation in layshafts, many of the rear hub bearings vary (especially some Italian ones), with the bearing protruding too far into the casing, which then pushes the layshaft even closer to the endplate. You might want to consider this factor too.

Good luck.

Adam

[john.t5]

Thanks for that Adam, I already had to change the rear hub besring from an mb to a casa. I'm thinking machining the groove invthe endplate is probably the most straightforward solution.

[Adam_Winstone]

Whilst you're at it you might want to consider chopping off the kickstart ramp and fitting the earlier LI type casing ramp, which then allows additional adjustment for the kickstart piston, otherwise I could see you getting into issues with the teeth fouling on the 1st gear teeth. You may well get away with the GP type endplate but adjustment is limitied.

Best of luck with the modifications. All of your efforts will be rewarded once you have it sorted (people's poet!).

Adam